0385700 JOHNSON INST.CALBE ASSY., Long

Illustration 1 g00283070
(1) The dowels extend past the end of the cylinder block. Distance ... 10.0 0.5 mm (.39 .02 inch) (2) The dowels extend past the end of the cylinder block. Distance ... 10.0 0.5 mm (.39 .02 inch) (3) The dowels extend past the end of the cylinder block. Distance ... 10.0 0.5 mm (.39 .02 inch) (4) Cylinder liner
Illustration 2 g00455305
Section A-ABore diameters in the cylinder block for the cylinder block liners: Position (A) ... 151.50 0.03 mm (5.965 .001 inch) Position (B) ... 149.8 0.3 mm (5.898 0.012 inch) Position (C) ... 148.00 0.03 mm (5.827 .001 inch) Position (D) ... 141.90 0.15 mm (5.587 .006 inch)
Illustration 3 g00283159
(5) Diameter of the camshaft bores ... 81.000 0.015 mm (3.1890 .0006 inch) (6) Tighten the bolt that holds the piston cooling jet to the following torque. ... 35 7 N m (26 5 lb ft) (7) Distance from the centerline of the crankshaft bore to the top surface of the cylinder block ... 387.00 mm (15.236 inch)The flatness of the top contact surface of the cylinder block must be within 0.05 mm (.002 inch) for any 150 mm (5.9 inch) section of the surface. (8) Width of the main bearing cap ... 175.000 0.020 mm (6.8898 .0008 inch)Width in cylinder block for the main bearing cap ... 175.000 0.018 mm (6.8898 .0007 inch) (9) Distance from the centerline of the crankshaft to the bottom surface of the cylinder block ... 120.0 mm (4.72 inch) (10) Main bearing cap boltsUse the following procedure in order to install the main bearing cap bolts:
Orient the main bearing cap correctly. The part number on the main bearing cap must face to the right and to the front face of the block. Also, the tab slots that are in the block and the main bearing caps must be adjacent.Note: The main bearing caps are marked with identification numbers 1 through 7. Install the main bearing caps into the correct positions.
Lubricate the main bearing cap bolts. Use "SAE 30W" oil or molybdenum grease to lubricate the threads and the washer face.
Tighten the main bearing cap bolts.Tighten bolts to the following torque. ... 95 5 N m (70 4 lb ft)
Put an alignment mark on each cap and bolt.Rotate the bolts in the clockwise direction. ... 90 5 degrees (11) Bore in the cylinder block for the seven main bearings ... 116.000 0.013 mm (4.5669 .0005 inch)Note: All of the measurements for the main bearing bore must be made before the main bearing cap is disassembled.
Illustration 4 g00283161
View B-BThe camshaft bearings are installed into the cylinder block at the values that follow.
Table 1
Serial Number Breaks    
Position     1YN1-1YN1274     1YN1275-Up     2PN1-2PN1084     2PN1085-UP    
A    
35.20 mm (1.386 inch)    
35.20 mm (1.386 inch)    
35.20 mm (1.386 inch)    
35.20 mm (1.386 inch)    
B    
189.50 mm (7.461 inch)    
191.20 mm (7.528 inch)    
189.50 mm (7.461 inch)    
191.20 mm (7.528 inch)    
C    
345.50 mm (13.602 inch)    
347.20 mm (13.669 inch)    
345.50 mm (13.602 inch)    
347.20 mm (13.669 inch)    
D    
501.5 mm (19.744 inch)    
503.20 mm (19.811 inch)    
501.5 mm (19.744 inch)    
503.20 mm (19.811 inch)    
E    
657.50 mm (25.886 inch)    
659.20 mm (25.953 inch)    
657.50 mm (25.886 inch)    
659.20 mm (25.953 inch)    
F    
813.50 mm (32.028 inch)    
815.20 mm (32.094 inch)    
813.50 mm (32.028 inch)    
815.20 mm (32.094 inch)    
G    
954.10 mm (37.563 inch)    
954.20 mm (37.567 inch)    
954.10 mm (37.563 inch)    
954.20 mm (37.567 inch)    
Camshaft bearings must be installed into their correct position. Failure to do so will result in engine damage.
Illustration 5 g00283162
View C-CNote: Illustration 5 represents camshaft bearing 7. (12) Bearing joint (A) Bearing oil hole at a 45 degree angle
Illustration 6 g00391637
View D-DNote: Illustration 6 represents camshaft bearings 2 through 6. (13) Bearing joint (14) Oil holeSh